Designers perform early-stage formative usability tests with low-fidelity prototypes to improve the design of new products. This low-tech prototype style reduces the manufacturing resources but limits the functions that can be assessed. Recent advances in technology enable designers to create low-fidelity 3D models for users to engage in a virtual environment. Three-dimensional models communicate design concepts and are not often used in formative usability testing. The proposed method discusses how to create a virtual replica of a product by assessing key human interaction steps and addresses the limitations of translating those steps into a virtual environment. In addition, the paper will provide a framework to evaluate the usability of a product in a virtual setting, with a specific emphasis on low-resource online testing in the user population. A study was performed to pilot the subject’s experience with the proposed approach and determine how the virtual online simulation impacted the performance. The study outcomes demonstrated that subjects were able to successfully interact with the virtual replica and found the simulation realistic. This method can be followed to perform formative usability tests earlier and incorporate subject feedback into future iterations of their design, which can improve safety and product efficacy.